Technology Forum - Indoneusa - Gas Engines (Oct.2014) V2

SHELL LUBRICANTS TECHNOLOGY SEMINAR:
IMPROVING OPERATIONAL EFFICIENCY OF

POWER ENGINES
How the right engine oil can

help you get the most out your
engines
Indonesia, Oct. 2014
Praveen Nagpal
Product Application Specialist – Shell Global Solutions
Copyright of Shell Australia October 2013 1

AGENDA
Key Learning Objectives:

 Gain insights of trends for stationary power engines
 Discuss the challenges of Gas Engines.
 Understand how the right gas engine oil can help improve reliability
& reduce maintenance costs
 Discover the benefits of using the right gas engine oil through real life
examples

TOPICS
 Stationary Power Engines – what’s changing

 Technology trends in Gas Engines
 Typical Challenges for gas engine oils
 Shell Mysella Portfolio
 Shell Mysella S5 N
 Shell Mysella S5 S
 Future Developments

CHANGES WHICH IMPACT STATIONARY ENGINES
GAS RESOURCES ARE PLENTIFUL, GROWING AND
Natural gas will play an increasingly GEOGRAPHICALLY DIVERSE
important role:
 Abundant global gas resources, long North America
Europe Eurasia
term security, low emission, cheaper

cost, massive investment on new
Middle East
Africa Asia Pacific
production and infrastructure. South America
 Increase utilisation of non conventional Conventional Gas Resources

Unconventional Gas Resources
gases like landfill, bio & sewage gas in

specific markets
THE ECA TIMETABLE IS WELL ESTABLISHED
Marine legislation creating uncertainty
regarding the future use of heavy fuel oil:
 LNG exhibits a long term viable solution
that reduces exposure from global S
specifications
 Overall impact on HFO and distillate
use in power engines unclear but cost
US ECA
volatility will remain

INTODUCTION: EXAMPLES OF NEW GAS ENGINES
GE JENBACHER J920 MTU SERIES 4000
MWM TCG 2032
Copyright of Shell Australia June 2012 5

GAS ENGINES TECHNOLOGY DEVELOPMENT
Trends in Gas Engines Creating Challenges for Lubricant

 Higher power density engines (BMEP),  Dry and hot combustion
Higher efficiency  Sensitive to deposits
 Optimized combustion chamber design  Sensitive to detonation/pre-ignition
(smaller piston top land, steel pistons)
 Special demands on oil lead to
 Lower specific engine oil consumption ageing and deterioration
(g/kWh) to meet particulate emission
 Application of exhaust gas heat
standards and for the benefit of catalytic
exchangers and aftertreatment devices
converter’s lifespan
 Application of catalytic converters
 Reduced Oil Life

 Increased operational and
maintenance costs
ENGINE TRENDS AND THE IMPACT ON THE LUBRICANT
Higher BMEP / power output Non-conventional gases

Increased combustion chamber Non-natural gases may contain
temperatures and pressures place many contaminants:
more stress on the lubricant and  Halogens which create acids »
can cause: increased engine corrosion and
 Rapid aging (oxidation, reduced oil life
nitration, BN depletion) »  Siloxanes which create hard
increased lubrication and deposits » increased engine
maintenance costs wear
 Creation of deposits » increased
Siloxanes can
engine wear
cause severe
deposit formation

GAS ENGINES LUBRICATION CHALLENGES
Protection
 Against Knocking or Detonation
 Ash Deposits in combustion chamber
 Ring Groove Deposits
 Valve Seat Recession
System efficiency
 Catalyst Ageing
 Boiler Fouling (CHP)
 Intercooler fouling (Recirculation of
crankcase gases)
Oil Life:
 Limited by
 Higher mechanical and thermal stress
 Oxidation, Nitration
Smaller sump, low lube oil consumption
Copyright of Shell Australia
 June 2012 8
GAS ENGINES LUBRICATION CHALLENGES - PROTECTION
Knocking – Oil Related Knocking – Oil Related
Ash removed
by impact of
knocking
Piston erosion
due to knocking
Congealed
spots of piston
material
Ring Groove Deposits
Required feature of oil:

Protection from knocking or detonation, ash deposits in
combustion chamber, ring groove deposits valve seat recession
GAS ENGINES LUBRICATION CHALLENGES –
SYSTEM EFFICIENCY
Air Cooler Clogging Boiler Fouling
Required Features of Oil

Maintain system efficiency by preventing boiler fouling (CHP), intercooler
fouling (Recirculation of crankcase gases), catalyst ageing, spark plugs
deposits
TRENDS IN ASH LEVELS AND OIL LIFE
Nowadays manufacturers have strong
Categorisation of gas engine oil
preference for low ash oils
 Valve recession problems less severe Zero ash:
than in the past. Ash content = 0%
 Provides sufficient protection against Low ash:

corrosion (natural gas) Ash content < 0.6 % m/m
 Reduce combustion chamber deposits,
fouling of turbine, catalyst and boilers Medium ash:
0.6% < ash content < 1.0 % m/m
Trends in oil consumption
 Low oil consumption as a result of High ash content: > 1.0 %
improved engine designs
 Low oil consumption is critical to
 Oil consumption of modern gas
prevent catalyst and boiler fouling
engines can be as low as 0.1
and to meet particulate emission
g/kWh
standards

Balancing the lube oil ash
Excellent state after 4800 running hours

on Mysella S5 N
Excessive ash deposits, risk of

channeling
Copyright of Shell Global Solutions International B.V.

Excellent state after 4800

running hours at Mysella S5 N
Excessive ash deposits

COST OPTIMISATION & THE ROLE OF LUBRICANTS
Plant managers look to operate their equipment as efficiently as possible:
 Increasing availability and reliability
 Extending
overhaul intervals and
component lifetime
 Reduced fuel and lubricant consumption
 Reducing unplanned maintenance/shutdowns
AND LUBRICANTS PLAY A KEY ROLE IN THIS BECAUSE…

 Their primary role is to keep the engine clean and free from deposits – reducing wear and
component costs
 Lubrication and maintenance costs will increase if the lubricant ages rapidly
 A good lubricant and OCM strategy will help an engine operate at maximum efficiency
whilst, in severe cases, a poor lubricant can cause engine failure
MAINTAINING ENGINE MAXIMISING OIL LIFE

PROTECTING THE ENGINE
EFFICIENCY
SHELL MYSELLA GAS ENGINE OILS: DESIGNED,
DEVELOPED, RIGOROUSLY TESTED AND VALIDATED
Copyright of Shell Australia 15

Excellent state after 11000

running hours on Mysella S5 N
Excessive ash deposits

MYSELLA S5 N VS. MAIN STREAM OIL- BETTER
VISCOSITY CONTROL AND BN RETENTION
Shell Mysella S3 N Shell Mysella S5 N

MYSELLA S5 N VS. MAIN STREAM OIL- BETTER
OXIDATION AND NITRATION RESISTANCE
Shell Mysella S3 N Shell Mysella S5 N

GE JENBACHER 620 AT 20 BAR BMEP
AFTER 10112 HRS ON MYSELLA S5 N4 (ODI >8000HRS)
Copyright of Shell Australia

SHELL MYSELLA S5 N DELIVERS EXCELLENT Formerly
Mysella XL
CLEANLINESS: DEMONSTRATED
Caterpillar 3516B Generator Drive after 9960 hours
Combustion chamber
cleanliness is critical for
component protection and
engine efficiency

SHELL MYSELLA S5 N DELIVERS EXCELLENT Formerly
Mysella XL
CLEANLINESS: DEMONSTRATED
Clogged fins of air cooler 10,000 Clean fins of air cooler 5,000
hours on commercial product hours on Mysella S5 N
Cleaner Intercoolers: Recirculation of crank case breathing gases

Excellent cleanliness for the heat recovery boilers, turbochargers and intercoolers,
thus enhancing energy efficiency.

Mysella S5 N – Field Experience
Wartsila 20V34SG after

16000 hrs without oil change

INDRAPRASTHA GAS LIMITED - INDIA

DIFFERENT GASES, DIFFERENT CHALLENGES
BIOGAS
 From anaerobic digestion of organic
material
 Normally contains H2S and NH3
LANDFILL GAS
 Gas from waste dumping grounds
 Usually contains compounds like H2S,
halogenated hydrocarbons e.g. Cl and F
and siloxanes
SEWAGE GAS
 Gas produced from anaerobic digestion of
from wastewater treatment plants (WWTPs)
 Normally contains H2S and siloxanes

CHALLENGES WITH SOUR GASES
LIMITATONS COMMON PROBLEMS

 Low or variable gas  Acid attack
quality
 Combustion chamber and valve
 Low energy content, deposit build-up and abrasive wear
usually contains
 Liner lacquering
moisture
 Short oil life
 Acidic in nature
 Reduced engine efficiency
 Increased operational and maintenance costs

 Corrosion-related failures

ADDRESSING THE SOUR GAS CHALLENGE
 Gas treatment/conditioning
 Frequent maintenance
 Frequent oil changes
 Using tailor-made oil for sour gas applications

COMMON ISSUES: ACIDIC CORROSION
 Corrosive compounds formed

e.g. H2SO4, HF, HCL
 Corrosive on liners, piston ring
grooves and bearings
WHAT IS NEEDED FROM THE OIL?

 Good alkalinity to neutralise
acid – represented by BN
 Limit on ash content

COMMON ISSUES: COMBUSTION CHAMBER DEPOSITS
 SiO2 is formed & deposited in the

combustion chamber
 Result in knocking
Hard deposits can

lead to abrasive
wear e.g. liner
scuffing
WHAT IS NEEDED FROM THE OIL?

 Limit on ash content; Formation
of soft ash deposits

THE DIFFERENCE IN USING THE RIGHT OIL…
STANDARD OIL TAILOR-MADE FOR SOUR GAS:

SHELL MYSELLA S5 S

IDEAL CHARACTERISTICS: WHAT IS REQUIRED FROM AN
ENGINE OIL FOR SOUR GAS APPLICATIONS
 Neutralise acid and handle contaminants of different sour gas types
 Minimise deposits in combustion chamber
 High level of engine protection
 Ideally provide significantly longer life than conventional oils
 Comply with OEM ash content requirements
WHAT IS NEEDED FROM THE OIL? CONTRADICTORY REQUIREMENTS?

 High total base number (TBN)… BUT could cause more deposits?
 High TBN retention
 High resistance against oxidation and nitration

SHELL MYSELLA S5 S: LOW ASH OIL DESIGNED FOR SOUR
GAS APPLICATIONS
Excellent liner condition
 Significantly longer oil life in high-speed

And a cleaner piston in a GE Jenbacher
gas engines 312 engine burning landfill gas
 Designed for high efficiency
 Delivers excellent cleanliness
Shell Mysella S5 S has had >200,000

hours of successful experience

CASE STUDY 1: BIOGAS SITE, ITALY (CONT’D)
Cleaner cylinder
heads after 7425 oil
hours of biogas
operation
Cleaner piston
ring groves
Good liner condition,

no scuffing or damage
to honing marks

CASE STUDY 2: LANDFILL GAS SITE, PORTUGAL (CONT’D)
Cleaner piston
ring groves after
7500 oil hours
Good liner condition,

light lacquering, no
damage to honing
marks after 7500 h
Low level of ash

deposits, well
protected valves
Clean
crankcase
SHELL MYSELLA S5 S: STRONG PERFORMANCE IN LOW
TO SEVEREST SOUR GAS APPLICATIONS
 World’s energy demand is growing and will need to rely on different

sources of energy including biogas
 Biogas for energy generation has it challenges; Clear drive to
increase efficiency & profitability
 Choosing the right engine oil is an effective no/low capital solution
 Shell Mysella S5 S, developed after 5 years of R&D can:
 Offer significantly longer oil life

 Support higher engine efficiency
 Reduce oil consumption
 Deliver cleanliness
 With >200,000 hours of experience, the benefits of the oil are
demonstrated in many examples in the field
GAS ENGINE OIL FORMULATION
DEVELOPMENT
Shell Technology

RESEARCH & DEVELOPMENT PHASES
1 Product 2 3
Formulation Formulation
Development
Development Trials (In House)
Planning
4 5 6
Formulation Pre-launch OEM
Trials (On Sites) Field Trials Approval Trials
Product
Launch
3 Years*
KEY DRIVERS FOR NEW OIL DEVELOPMENTS
Technology Trends in Gas Engines Drivers for New Oil Development
 Higher power density engines  Address the requirement for

(BMEP), Higher efficiency modern gas engines.
 Optimized combustion chamber  Improved ODI compare to
design existing premium product.
 Lower specific engine oil  Better Deposit control in high
consumption (g/kWh) BMEP engines
 Improved BN retention and
oxidation resistance
Key Elements of New Oil Development
 Close co-operation with major OEMs

 Anticipate the future challenges.
 Effective customer feedback
 In house research based on end user feedback.
 Centralized
Copyright of Shell Australia Monitoring
Footervia LubeAnalyst Month 2010 38
GAS ENGINE OIL DEVELOPMENTS
 Shell Research & Development has strong

association with all leading gas engine OEMs
like Wartsila, MAN, GE-Jenbacher, Waukesha,
CAT, MWM
 Shell works closely with OEMs to understand
their new generation technologies and develop
solution for them
 Joint field trials to ensure that proven and
qualified products are available for end
customers. Some of recent new approvals are
New Approvals for Shell Mysella S5 S
New Approvals for Shell Mysella S5 N  GE-Jenbacher for series 2,3,4 and 6E
 MAN D&T medium speed engine in gas operation.  MWM- All series.
 CAT- MAK in GCM 34 gas engines. Approval  2G: Series 2,3
from  Caterpillar Endurance test
 MTU: Series 4000, L62,63,64 and 33
 MAN T&B – Fiedl Trial in progress
GAS ENGINE OIL FUTURE DEVELOPMENTS
New developments under discussion with

leading OEMs
 Long life and improved cleanliness
lubricants for highly efficient, high BMEP
modern design engines with smaller
piston top land, steel pistons
 Lubricants which could offer improved
engine efficiency – lessons from truck
engines?
 Impact of NESHAP RICE in US
 Single oil for dual fuel operation in DF

engines
“The trucks running on Shell Rimula R6 LME showed
 Shell is working to accelerate the
a reduction in fuel consumption of 2% on average
adoption of LNG in transport, marine
compared with a standard 10W-40 reference oil.*”
and power generation

Q&A

Technology Forum - Indoneusa - Gas Engines (Oct.2014) V2

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SHELL LUBRICANTS TECHNOLOGY SEMINAR:

IMPROVING OPERATIONAL EFFICIENCY OF

How the right engine oil can

Indonesia, Oct. 2014

Copyright of Shell Australia October 2013 1

Key Learning Objectives:

 Discuss the challenges of Gas Engines.

Copyright of Shell Australia October 2013 2

 Stationary Power Engines – what’s changing

Copyright of Shell Australia October 2013 3

term security, low emission, cheaper

Africa Asia Pacific

production and infrastructure. South America

 Increase utilisation of non conventional Conventional Gas Resources

gases like landfill, bio & sewage gas in

volatility will remain

GE JENBACHER J920 MTU SERIES 4000

MWM TCG 2032

Copyright of Shell Australia June 2012 5

Trends in Gas Engines Creating Challenges for Lubricant

 Reduced Oil Life

Higher BMEP / power output Non-conventional gases

Copyright of Shell Australia June 2012 7

Ring Groove Deposits

Required feature of oil:

Air Cooler Clogging Boiler Fouling

Required Features of Oil

 Provides sufficient protection against Low ash:

Copyright of Shell Australia October 2013 11

Excellent state after 4800 running hours

Excessive ash deposits, risk of

Copyright of Shell Global Solutions International B.V.

Excellent state after 4800

Excessive ash deposits

Copyright of Shell Global Solutions International B.V.

AND LUBRICANTS PLAY A KEY ROLE IN THIS BECAUSE…

MAINTAINING ENGINE MAXIMISING OIL LIFE

Copyright of Shell Australia 15

Excellent state after 11000

Excessive ash deposits

Copyright of Shell Global Solutions International B.V.

Copyright of Shell Australia June 2012 18

Copyright of Shell Australia June 2012 19

Copyright of Shell Australia

Copyright of Shell Australia October 2013 21

Cleaner Intercoolers: Recirculation of crank case breathing gases

Copyright of Shell Australia October 2013 22

Wartsila 20V34SG after

Copyright of Shell Global Solutions International B.V.

Copyright of Shell Australia October 2013 24

Copyright of Shell Australia 25

LIMITATONS COMMON PROBLEMS

 Increased operational and maintenance costs

Copyright of Shell Australia 26

 Frequent oil changes

 Using tailor-made oil for sour gas applications

Copyright of Shell Australia 27

 Corrosive compounds formed

WHAT IS NEEDED FROM THE OIL?

Copyright of Shell Australia 28

 SiO2 is formed & deposited in the

Hard deposits can

WHAT IS NEEDED FROM THE OIL?

Copyright of Shell Australia 29